Apparatus and method for making a component an attachment molded thereon and an insert

ABSTRACT

An apparatus and method for manufacturing an attachment including an attachment molded thereon and an insert is shown. The insert is treated so that the lubricant used while affixing the insert to the component does not seep into the insert. The component is processed and inserted into a mold, in which molding material is introduced. Because the lubricant did not seep into the insert, it is not squeezed out during the molding process and does not impede the flow of the molding material. The molding material forms the attachment, which is molded onto the component. The attachment has less defects than attachments molded onto the component using methods of the prior art.

CROSS REFERENCE TO RELATED APPLICATION DATA

This Application claims the benefit of priority of provisional U.S. Patent Application Ser. No. 60/642,630, filed Jan. 10, 2005.

BACKGROUND OF THE INVENTION

The present invention pertains to an apparatus and method for making a component including an attachment molded thereon and an insert for the component.

Components often have holes formed within the components. Inserts are affixed to the holes and allow the components to be assembled with other parts, typically to form an assembly that includes the component and the other parts that the component is assembled with. Attachments can then be molded onto the components by an injection molding process. The attachments can serve numerous purposes, such as providing a seal between the component and the other parts with which the component is assembled.

For example, windage tray type components work in conjunction with and are connected to other parts to form oil pan assemblies for the manufacture of engines, such as engines used in automobiles and other vehicles. FIGS. 1 and 1A show the windage tray 10 including holes 12 formed in its periphery 14, and ring inserts 16 affixed within the holes. The ring inserts 16 allow for the windage tray 10 to be connected to other parts to form the oil pan assembly.

The windage tray 10 separates oil in the sump of the engine from the crank assembly of the engine. To achieve improved separation, a gasket type attachment 18 is molded onto the windage tray 10. The gasket 18 functions as a seal and reduces oil seepage from the pan sump to the crank assembly. This increases engine efficiency and horsepower.

Problems, however, have arisen in molding attachments onto the components, including problems in molding the gasket 18 onto the windage tray 10. For example, the windage tray 10 is generally placed within a mold, and a molding material is introduced into the mold to form the gasket. However, But this process oftentimes results in a defective gasket 18 molded onto the windage tray. Specifically, the gasket is plagued by knit lines 20, as shown in FIG. 1A. Knit line defects 20 can render the entire tray useless and require another tray to be manufactured. Knit lines defects are prevalent in other components that incorporate holes, inserts and a molded on attachment as well.

Accordingly, there exists a need for an improved apparatus and method for manufacturing a component including an attachment molded thereon and an insert.

BRIEF SUMMARY OF THE INVENTION

An apparatus and method for manufacturing a component that includes an attachment molded thereon and an insert—reduces defects formed on the attachment. A machine is used to affix the insert to the component, and during the affixing process, the machine is lubricated by a lubricant. It has been found that the lubricant seeps into the insert. When the component is placed within a mold to mold the attachment onto the component, the lubricant seeps out of the insert. As a result, the lubricant impedes molding material from flowing within the mold and properly forming the attachment.

In the present invention, the insert is treated so that the lubricant does not seep into the insert. The insert is treated by covering a portion of the insert with a coating, and preferably, by dipping the insert into a coating. In a preferred embodiment, the coating dissolves in the molding material and includes zinc stearate. The molding material is formulated to dissolve or absorb the insert coating as the attachment is formed (which is thus molded onto the component).

In the manufacture of windage tray type components, a ring insert is covered in a coating, preferably, a zinc stearate coating. When the ring insert is affixed to the windage tray, the coating prevents lubricant from the affixing machine from seeping into the insert. When the windage tray and inserts are put into the mold and the molding material is introduced into the mold, lubricant does not seep out of the insert and as such, the molding material forms a gasket substantially free from knit line defects.

These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

FIG. 1 is a perspective isometric view of a prior art component having an attachment molded thereon and an insert;

FIG. 1A is an enlarged view of a portion of the prior art attachment showing defects;

FIG. 2 is a block diagram of one embodiment of a method of the invention;

FIG. 3 depicts a component and an insert pursuant to an embodiment of the invention;

FIG. 4 is a perspective view of a component having the insert affixed within a hole of the component and an attachment molded thereon; and,

FIG. 4A is an enlarged view of a portion of a gasket pursuant to an embodiment of the invention substantially free from defects.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated.

It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.

All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically do so within the text of this disclosure.

In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

One embodiment of the invention pertains to an apparatus and method for manufacturing components each including an attachment molded thereon and an insert, where there are fewer defects on the attachments as compared to components that are manufactured by prior art methods.

It has been found that defects caused in the attachment often arise when affixing the insert to the component. Specifically, stamping dies are used to affix the inserts to the component, and during the affixing (stamp) process, lubricant used to lubricate the stamping dies seeps into the inserts. The component having the insert affixed thereto is positioned within a mold. When molding begins, lubricant is squeezed out of the insert and enters areas of the mold, blocking areas where the molding material needs to flow and, thus, causing defects on the attachment.

Pursuant to a first embodiment of the invention, the insert is treated so that lubricant cannot enter or seep into the insert. The treated insert is affixed to the component. An attachment is molded onto the component and is free from molding defects caused by lubricant impeding molding material flow.

FIG. 2 shows a block diagram of a first embodiment of a method of the invention. At step 110, the insert 30 (best seen in FIG. 3) is treated to prevent lubricant from seeping into the insert. In a preferred embodiment, the insert 30 is treated by covering it with a coating, which in one embodiment, is achieved by dipping the insert into a coating bath. When applied to the insert 30, the protective coating prevents lubricant from seeping into the insert.

In one embodiment, the insert is a ring insert 30 formed from a powdered metal and cooperates with holes 32 within a windage tray 34. In a preferred embodiment, the coating dissolves when exposed to the molding material. In a most preferred embodiment, the coating is formed from a zinc stearate solution, such as Akrodip Z50/50 diluted to about an 8% to 9% solution with water and having about a 1% amine rust inhibitor added to reduce and prevent oxidation of the insert 30.

Those of skill in the art will also appreciate that there are other methods and embodiments within the spirit and scope of the invention that may be used to treat the insert. For example, a resin may be inserted into the pores of the insert, which is typically performed under vacuum pressure. The resin prevents the lubricant from seeping into the insert. Those of skill in the art will appreciate that there are still other embodiments of treating the insert that are within the spirit and scope of the invention.

The embodiment of FIG. 2 shows that the insert is dried at step 120. In one embodiment, the insert 30 is dried by applying hot air, and in a preferred embodiment, by applying forced air at a temperature of about 212° F. for about fifteen minutes. In other embodiments, the inserts 30 may be dried in other manners.

The treated insert 30 is then affixed to the component 34 at step 130. For example, windage tray type components 34 (FIG. 3) include windage tray bodies 36 and windage tray perimeters 38. Holes 32 are formed in the windage tray perimeters 38, and ring inserts 30 are positioned within the holes 32. In one embodiment, the ring insert 30 is formed from a metal that is softer than a metal that forms the windage tray 34.

The ring insert 30 is affixed to the windage tray 34 by, for example, a staking process. Specifically, an outwardly tapering stake of a stamping die is inserted within the ring insert and the hole (within which the ring insert is positioned). The stake is pressed down into the ring insert to expand the ring insert 30 so that it expands and abuts the inner circumference of the hole 32 within the windage tray 34. During this process, the ring insert 30 may be exposed to lubricant used to lubricate the stamping die—but, because the insert has been treated, the lubricant does not seep into the insert. Inserts 30 affixed to the components are shown in FIG. 3.

It should be noted that, when a resin is used to treat the insert, because the resin has a tendency to harden the ring insert, the ring insert might chip during staking. As a result, the ring insert may not be as readily affixed to the hole within the windage tray. Those of skill in the art will appreciate that the spirit and scope of the invention covers other embodiments that use different affixing methods (for example, staking) in which a machine requiring lubrication is used to affix the insert to the component.

At step 140, the component 34 is processed. Different components are processed in different manners depending on the specific application that the component will be used in. For windage tray type components 34, the component is washed, for example, by placing it in a parts washer. The windage tray 34 is then dried and covered with an adhesive. In one embodiment, the windage tray 34 is dipped in an adhesive, such as, for example, Chemlok Y4310 diluted to a 1:1 ratio with methanol. The windage tray 34 may then be dried, such as, for example, by air drying the windage tray for thirty minutes.

At step 150, the component 34 is positioned within a mold that defines the attachment 40. Molding material is introduced into the mold. In one embodiment, the molding material is a compound, preferably a polyacrylate compound. As provided above, when a coating that is soluble in the molding material, such as zinc stearate, is used, it dissolves in and/or is absorbed by the molding material. The dissolution and/or absorption of the coating reduces the possibility of the coating (as opposed to the lubricant from the affixing machine) to impede molding material flow and, thus, reduces the possibility of additional defects caused by the coating. The component 34 with the attachment 40 molded thereto is removed with a substantially lower risk of defects, as shown in FIGS. 4 and 4A.

At step 160, the component 34 is cured to the attachment 40, and in a preferred embodiment, is cured for about two hours at about 350° F. Those of skill in the art will appreciate that, although a windage tray 34 and ring insert 30 have been described, the scope and spirit of the invention covers other components that require an insert to be affixed thereto and an attachment to be molded thereto.

From the foregoing it will be observed that numerous modifications and variations can be made to the invention without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or to be inferred. The disclosure is intended to cover all such modifications as fall within the scope of the invention. 

1. A method for making a component including an attachment molded thereon and an insert, the method comprising: treating the insert to prevent lubricant used in a affixing step from entering into the insert; the affixing step including affixing the insert to a hole formed in the component with a machine and lubricating the machine with the lubricant; processing the component; and, molding an attachment to the component.
 2. The method of claim 1, wherein the treating step further includes covering at least a portion of the insert with a coating.
 3. The method of claim 2, wherein the treating step further includes dipping the insert into a coating bath.
 4. The method of claim 2, wherein the treating step further includes covering at least a portion of the insert with a coating that is soluble in a molding material.
 5. The method of claim 2, wherein the treating step further includes covering at least a portion of the insert with a coating that includes zinc stearate.
 6. The method of claim 1, further including the step of drying the insert.
 7. The method of claim 1, wherein the affixing step further includes staking the insert to the hole.
 8. The method of claim 1, wherein the processing step further includes washing the component, drying the component, applying adhesive to the component, and re-drying the component.
 9. The method of claim 1, wherein the molding step further includes inserting the component within a mold that defines the attachment and introducing a molding material into the mold.
 10. The method of claim 9, wherein the molding step further includes dissolving or absorbing the coating with the molding material.
 11. A component manufactured by the method of claim
 1. 12. A component comprising: a component body; a component perimeter integral with the component body, the component perimeter having a hole formed therein; an insert being shaped to conform to the hole and being affixed to the hole, at least a portion of the insert being covered with a coating at a first point in time, wherein, when the coating covers the insert, the coating is configured to prevent lubricant from entering into the insert; and, an attachment formed from a molding material and being molded onto the component perimeter, the molding material dissolving or absorbing the coating at a second point in time.
 13. The component of claim 12, wherein the component body further includes a windage tray body and the component perimeter includes a windage tray perimeter.
 14. The component of claim 12, wherein the hole is defined by a circle and the insert further includes a ring insert.
 15. The component of claim 12, wherein the component body and perimeter are formed from a first metal and the insert is formed from a second metal, the second metal being softer than the first metal.
 16. The component of claim 12, wherein the coating further includes a zinc stearate solution.
 17. The component of claim 12, wherein the molding material further includes a polyacrylate compound.
 18. A method for molding an attachment onto a component that includes a hole formed therein, the method comprising: treating means for treating an insert so that a lubricant used by an affixing means cannot enter into the insert; affixing means for affixing the insert to the hole formed in the component; lubricating means for lubricating the affixing means with the lubricant; processing means for processing the component; and, molding means for molding the attachment to the component.
 19. The method for molding of claim 18, wherein the treating means further includes covering means for covering the insert with a coating. 